Abstract
The present research work aimed to study the effects of cutting environments and conditions on tool wear and residual stresses induced by orthogonal cutting of AA6061-T6. Cutting environments included dry- and flood-coolant modes and cutting conditions consisted of cutting speed and feed rate. A 2D finite element (FE) model was developed to predict tool wear and residual stresses and was validated by experimental measurements including machining forces, tool wear, and residual stresses. This was obtained by exploring various magnitudes of the shear friction factor and heat transfer coefficient and choosing proper coefficients using the calibration of the predicted results with the measured ones. The experimental results showed that the effect of cutting environment including dry and flood-coolant modes was negligible on machining forces. The experimental investigation also demonstrated that increasing feed rate raised machining forces, tool wear and residual stresses in both cutting environments. Low Speed Cutting (LSC) led to the highest value of tool wear and High Speed Cutting (HSC) provided the lowest values of resultant machining forces and residual stresses in both modes. Flood-coolant mode reduced tool wear and slightly decreased tensile residual stresses in comparison with dry mode. As a result, low feed rate and high-speed cutting under flood-coolant mode were proposed in order to improve tool wear and residual stress in orthogonal cutting of AA6061-T6.
Highlights
Published: 31 July 2021Machining operations are commonly used in the aerospace industry to produce the desired shape of components as reported by Javidikia et al [1] and Touazine et al [2]
The present research studied the impacts of cutting environments and conditions on machining forces, tool wear and residual stresses in the orthogonal cutting of AA6061-T6
The experimental results demonstrated that machining forces almost were not affected by the cutting environment including dry and flood-coolant modes
Summary
Machining operations are commonly used in the aerospace industry to produce the desired shape of components as reported by Javidikia et al [1] and Touazine et al [2]. Coelho et al [17] performed FE modeling of orthogonal turning of AISI 4340 steel using the Abaqus software to predict tool wear and machining forces with uncoated and coated carbide inserts. Maranhao and Davim [21] developed a FE model of orthogonal cutting of AISI 316 steel to predict the effect of feed rate on residual stress using the AdvantEdge software (produced by Third Wave Systems). Qi et al [24] analyzed the effect of different machining parameters on surface residual stress during dry cutting AISI 1045 steel Their results showed that the surface residual stress is not sensitive to the variation of cutting speed. As seen in the above-mentioned papers, very little information is available in the published literature on the effect of different cutting environments and high-speed machining on tool wear induced by orthogonal cutting of metals.
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